US7950503B2 - Electric disk brake, caliper for the electric disk brake, motor/controller unit for the electric disk brake, and method for assembling the caliper for the electric disk brake - Google Patents

Electric disk brake, caliper for the electric disk brake, motor/controller unit for the electric disk brake, and method for assembling the caliper for the electric disk brake Download PDF

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Publication number
US7950503B2
US7950503B2 US11/723,313 US72331307A US7950503B2 US 7950503 B2 US7950503 B2 US 7950503B2 US 72331307 A US72331307 A US 72331307A US 7950503 B2 US7950503 B2 US 7950503B2
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motor
rotor
caliper
electric
disk
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US11/723,313
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US20070227838A1 (en
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Hiroshi Shigeta
Takayasu Sakashita
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Hitachi Ltd
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Hitachi Ltd
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Assigned to HITACHI, LTD. reassignment HITACHI, LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SAKASHITA, TAKAYASU, SHIGETA, HIROSHI
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00—Parts or details
    • F16D65/14—Actuating mechanisms for brakes; Means for initiating operation at a predetermined position
    • F16D65/16—Actuating mechanisms for brakes; Means for initiating operation at a predetermined position arranged in or on the brake
    • F16D65/18—Actuating mechanisms for brakes; Means for initiating operation at a predetermined position arranged in or on the brake adapted for drawing members together, e.g. for disc brakes
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00—Parts or details
    • F16D65/38—Slack adjusters
    • F16D65/40—Slack adjusters mechanical
    • F16D65/52—Slack adjusters mechanical self-acting in one direction for adjusting excessive play
    • F16D65/56—Slack adjusters mechanical self-acting in one direction for adjusting excessive play with screw-thread and nut
    • F16D65/567—Slack adjusters mechanical self-acting in one direction for adjusting excessive play with screw-thread and nut for mounting on a disc brake
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2121/00—Type of actuator operation force
    • F16D2121/18—Electric or magnetic
    • F16D2121/24—Electric or magnetic using motors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2125/00—Components of actuators
    • F16D2125/18—Mechanical mechanisms
    • F16D2125/20—Mechanical mechanisms converting rotation to linear movement or vice versa
    • F16D2125/34—Mechanical mechanisms converting rotation to linear movement or vice versa acting in the direction of the axis of rotation
    • F16D2125/36—Helical cams, Ball-rotating ramps
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2125/00—Components of actuators
    • F16D2125/18—Mechanical mechanisms
    • F16D2125/44—Mechanical mechanisms transmitting rotation
    • F16D2125/46—Rotating members in mutual engagement
    • F16D2125/48—Rotating members in mutual engagement with parallel stationary axes, e.g. spur gears
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2127/00—Auxiliary mechanisms
    • F16D2127/06—Locking mechanisms, e.g. acting on actuators, on release mechanisms or on force transmission mechanisms
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2250/00—Manufacturing; Assembly
    • F16D2250/0084—Assembly or disassembly

Definitions

  • the present invention relates to an electric disk brake having an electric motor to press a brake pad against a disk rotor to exert a braking force; a caliper for the electric disk brake; a motor/controller unit adapted for use in the electric disk brake; and a method for assembling the caliper for the electric disk brake.
  • Examples of electric disc brakes are disclosed in Japanese Patent Public Disclosure No. 2000-304076, and in Japanese Patent Public Disclosure No. 2003-137081. In these references, electric disc brakes are described which use a rotary-to-linear motion conversion mechanism such as a ball screw mechanism or a ball ramp mechanism to convert a rotary motion of a rotor of an electric motor to a linear motion of a piston, which is adapted to press a brake pad against a disk rotor to exert a braking force. Further, these electric disk brakes use a sensor to detect a force (or an amount of displacement) which a driver applies to a brake pedal. Based on a detected value, rotation of the electric motor is controlled to exert a desired braking force.
  • a rotary-to-linear motion conversion mechanism such as a ball screw mechanism or a ball ramp mechanism to convert a rotary motion of a rotor of an electric motor to a linear motion of a piston, which is adapted to press a brake pad against a disk rotor to exert a
  • a claw portion of a brake caliper is provided with a ball ramp mechanism, a speed reduction mechanism, and so on, each of which are sub-assembled to form an opening/closing mechanism. Further, an electric motor, a rotational-position sensor, and so on are sub-assembled in a case and a cover to form a motor mechanism. Subsequently, the opening/closing mechanism and the motor mechanism are joined together in an assembling process.
  • the assembling process which involves sub-assembly steps for the mechanisms mentioned, is aimed at improving assembly efficiency.
  • the electric disk brake disclosed in Japanese Patent Public Disclosure No. 2003-137081 is provided with a drive controller for controlling operation of an electric motor, the drive controller being integrated into a brake caliper to simplify wiring of a power line and a control-signal line connecting a vehicle-mounted controller, which is mounted on a vehicle body, and a brake caliper so as to reduce an adverse effect of noise and a power loss.
  • constituent components including the piston, the rotary-to-linear motion conversion mechanism, the electric motor, and the drive controller are required to be individually incorporated into the brake caliper. This makes assembling and disassembling operations complicated. Further, an operation check can be conducted only after all of the constituent components have been assembled. This makes it difficult to detect any defect in each component during a manufacturing or repairing process.
  • An object of the present invention is to provide an electric disk brake having constituent units that can be operated and inspected before being assembled and that can be assembled easily, a caliper for the electric disk brake, a motor/controller unit for the electric disk brake, and a method for assembling a caliper for the electric disk brake.
  • the present invention provides a caliper for an electric disk brake, the caliper comprising:
  • a rotary-to-linear motion conversion mechanism for converting a rotary motion of the electric motor to a linear motion to transmit the linear motion to the pressing member, the pressing member being moved forward according to rotation of the electric motor to press the brake pad against the disk rotor to exert a braking force;
  • a motor/controller unit which is formed by integrating the electric motor and the controller for controlling the electric motor.
  • the present invention provides a motor/controller unit for an electric disk brake, the motor/controller unit comprising:
  • the motor being adapted to be operably connected to a rotary-to-linear motion conversion mechanism of the electric disk brake for converting a rotary motion of the motor to a linear motion to apply a pressure to a brake pad;
  • controller for controlling the motor, the controller being integrated with the motor.
  • the present invention provides a method for assembling a caliper for an electric disk brake for pressing a brake pad against a disk rotor to exert a braking force
  • the caliper including:
  • a rotary-to-linear motion conversion mechanism for converting a rotary motion of the motor to a linear motion to transmit the linear motion to the pressing member, such that the motor is rotated by a controller for controlling the motor, and the pressing member is moved forward according to rotation of the motor,
  • an electric disk brake including a caliper that has a pressing member for pressing a brake pad; a motor; a rotary-to-linear motion conversion mechanism for converting a rotary motion of the motor to a linear motion to transmit the linear motion to the pressing member, the pressing member being adapted to move forward according to rotation of the motor to press the brake pad against the disk rotor to exert a braking force, wherein,
  • the caliper defines a cylinder for containing the piston, the rotary-to-linear motion conversion mechanism, and the motor;
  • the motor is integrated as a motor unit including a motor stator, a motor rotor, and a motor case for containing the motor stator and the motor rotor, an outer circumferential portion of the motor case being abutted on an inner circumferential portion of the cylinder to support the motor.
  • FIG. 1 is a longitudinal cross-sectional view of an electric caliper of an electric disk brake according to a first embodiment of the present invention.
  • FIG. 2 is a perspective view of the electric disk brake according to the first embodiment of the present invention.
  • FIG. 3 is a side view of the electric disk brake of FIG. 2 as it appears when it is viewed from a claw portion of the electric disk brake.
  • FIG. 4 is a front view of the electric disk brake of FIG. 2 .
  • FIG. 5 is a side view of the electric disk brake of FIG. 2 as it appears when it is viewed from a piston of the electric disk brake.
  • FIG. 6 is a plan view of the electric disk brake of FIG. 2 .
  • FIG. 7 is an exploded perspective view of the electric caliper of FIG. 1 .
  • FIG. 8 is an exploded perspective view of the electric caliper of FIG. 1 as it appears when it is viewed from a different angle from FIG. 7 .
  • FIG. 9 is a longitudinal cross-sectional view of an electric caliper of an electric disk brake according to a second embodiment of the present invention.
  • FIG. 10 is a longitudinal cross-sectional view of an electric caliper of an electric disk brake according to a third embodiment of the present invention.
  • FIG. 11 is a longitudinal cross-sectional view of an electric caliper of an electric disk brake according to a fourth embodiment of the present invention.
  • an electric disk brake 1 of the present embodiment is of a caliper floating type which comprises: a disk rotor 2 adapted to rotate with a wheel; a carrier 3 secured to a non-rotating portion (not shown) of a vehicle body such as a suspension member; a pair of brake pads 4 and 5 disposed on opposite sides of the disk rotor 2 and supported by the carrier 3 ; and an electric caliper (caliper) 7 disposed to straddle the disk rotor 2 and supported by a pair of slide pin bolts 6 so as to move relative to the carrier 3 along an axis of the disk rotor 2 .
  • the electric caliper 7 comprises a caliper body 8 , a piston unit 9 , and a motor/controller unit 10 .
  • the caliper body 8 comprises: a cylinder 11 defining a through-hole, an end of the through-hole being open to a surface of the disk rotor 2 ; a claw portion 12 extending from the cylinder 11 over the disk rotor 2 to an opposite side of the disk rotor 2 ; and a pair of bosses 13 being formed to extend from the cylinder 11 approximately in a direction of the diameter of the cylinder 11 , and being provided with the respective slide pin bolts 6 , such that the cylinder 11 , the claw portion 12 , and the pair of bosses 13 are integrally formed.
  • the piston unit 9 is formed by integrating: a cylindrical piston (pressing member) 14 with a closed end; a ball ramp mechanism (rotary-to-linear motion conversion mechanism) 19 and a differential reduction mechanism 20 contained in the piston 14 ; and a pad wear compensation mechanism 21 .
  • the piston 14 is slidably fitted into the guide bore 15 of the caliper body 8 and is abutted against a brake pad 5 , such that engagement with the brake pad 5 prevents the piston 14 from rotating.
  • a portion between the piston 14 and the guide bore 15 is sealed with a dust seal 22 and a seal ring 23 .
  • the pressing member is not limited to a cylindrical piston with a closed end, as used in the present embodiment; but a piston with a T-shaped cross section, as shown in Japanese Patent Public Disclosure No. 2000-304076, can also be used as long as the guide bore 15 can be sealed.
  • the ball ramp mechanism 19 comprises: a linear-motion disk 24 fixed to a bottom surface of the piston 14 ; a rotary disk 25 capable of moving in rotational and axial directions; and a ball (rolling member) 28 fitted into a space between ball grooves (inclined grooves) 26 and 27 that are formed on opposing surfaces of the linear-motion disk 24 and the rotary disk 25 .
  • the rotary disk 25 is always urged by a spring 29 towards the linear-motion disk 24 .
  • the ball 28 rolls in the space between the inclined ball grooves 26 and 27 , causing the linear-motion disk 24 and the rotary disk 25 to move relative to each other in the axial direction, according to a rotational angle. In this way, rotary motion can be converted into linear motion.
  • the differential reduction mechanism 20 comprises: an eccentric shaft 30 ; a ring-shaped spur gear 32 having external teeth 32 A and 32 B, the spur gear 32 being rotatably fitted onto an eccentric portion 31 of the eccentric shaft 30 ; internal teeth 33 formed on the rotary disk 25 of the ball ramp mechanism 19 , the internal teeth 33 meshing with the external teeth 32 A of the spur gear 32 ; and a ring gear member 35 having internal teeth 34 which meshes with the external teeth 32 B of the spur gear 32 , the ring gear member 35 being supported so as to be capable of rotating relative to a rotary shaft of the eccentric shaft 30 .
  • One end of the eccentric shaft 30 is rotatably supported by the linear-motion disk 24 and the rotary disk 25 , while the other end of the eccentric shaft 30 is formed to extend into the motor/controller unit 10 , and an external spline 36 is formed on a tip of the other end of the eccentric shaft 30 .
  • One end of the ring gear member 35 is abutted via a thrust bearing 37 against an end of the rotary disk 25 . In this way, when the spur gear 32 is revolved by rotating the eccentric shaft 30 , differential rotation between the rotary disk 25 , which has the inner teeth 33 meshing with the external teeth 32 A of the spur gear 32 , and the ring gear member 35 , which has the internal teeth 34 meshing with the external teeth 32 B, is performed.
  • rotation of the other can be decelerated at a predetermined speed reduction ratio.
  • the pad wear compensation mechanism 21 comprises: a limiter 38 disposed between the linear-motion disk 24 and the rotary disk 25 of the ball ramp mechanism 19 ; an adjustment screw 16 connected to the ring gear member 35 of the differential reduction mechanism 20 ; and a wave washer 38 A disposed between the piston 14 and the adjustment screw 16 .
  • the limiter 38 has a torsion spring that urges the linear-motion disk 24 and the rotary disk 25 in a return direction with a certain play therebetween.
  • the adjustment screw 16 has a male thread (trapezoidal thread) 17 formed on an outer circumference thereof, the male thread 17 meshing with a female thread (trapezoidal thread) 18 formed on the cylinder 11 of the caliper body 8 .
  • the adjustment screw 16 is held by the wave washer 38 A with a certain retaining force so as not to rotate. When the adjustment screw 16 is rotated against this retaining force, relative rotation between the male thread 17 and the female thread 18 allows the adjustment screw 16 to move in the axial direction. Further, the adjustment screw 16 is adapted to receive a reaction force from the rotary disk 25 via the thrust bearing 37 and the gear member 35 and to transmit the force to the caliper body 8 via the male screw 17 and the female screw 18 .
  • the motor/controller unit 10 comprises: a motor 39 ; a resolver (rotation detection means) 40 for detecting a rotational position of the motor 39 ; a parking brake mechanism 41 for fixing the rotational position of the motor 39 ; and a drive controller (controller) 42 for controlling operation of the motor 39 , which are integrated by a base plate (plate member) 43 .
  • the motor 39 is provided with a cylindrical motor case 44 with a closed end, the cylindrical motor case 44 being made of an iron-based material.
  • the cylindrical motor case 44 is attached to a surface 43 A of the base plate 43 made of aluminum that is connected to an end portion of the caliper body 8 and is inserted into the adjustment screw 16 of the piston unit 9 .
  • a motor stator 45 comprising a coil and so on is secured to an inner circumferential portion of the motor case 44 .
  • Bearings 46 and 47 are disposed at openings of a bottom portion of the motor case 44 and the base plate 43 , respectively, such that a cylindrical motor rotor 48 is rotatably supported by the bearings 46 and 47 .
  • the motor case 44 is abutted on and supported by an inner circumferential surface of the cylinder 11 of the caliper body 8 so as not to move in a radial direction.
  • the motor rotor 48 has an internal spline 49 formed on an inner circumferential portion thereof, the internal spline 49 being engaged with the external spline 36 of the eccentric shaft 30 of the piston unit 9 , such that a rotational force can be transmitted between the motor rotor 48 and the eccentric shaft 30 , and the motor rotor 48 and the eccentric shaft 30 are able to move relative to each other in the axial direction.
  • the motor 39 is unitized with the motor case 44 and the base plate 43 . Therefore, the motor rotor 48 of the motor unit by itself can be rotated by applying an electrical current to the motor stator 45 ; and accordingly the motor unit can be inspected separately.
  • the resolver 40 comprises: a resolver stator 50 fixed to a surface 43 B of the base plate 43 opposite to the motor 39 ; and a resolver rotor 51 attached to a tip of the motor rotor 48 , that is opposed to the resolver stator 50 and inserted into the base plate 43 .
  • the resolver 40 is adapted to output an electric signal according to a relative rotation of the resolver stator 50 and the resolver rotor 51 , the electric signal indicating a rotational speed and a rotational position of the motor rotor 48 .
  • the parking brake mechanism 41 uses an electric actuator to operate a lock mechanism 52 , thereby locking the motor rotor 48 so as to prevent it from rotating.
  • the drive controller 42 is a control circuit that is placed on a board attached to a side of the base plate 43 opposite to the motor 39 .
  • the drive controller 42 is connected via a wire 45 A to the motor 39 and is also connected via a wire 50 A to the resolver 40 .
  • the drive controller 42 is adapted to transmit a drive signal to the motor 39 to control rotation of the motor 39 , based on: a braking-force signal emitted in response to a brake-pedaling operation by a driver or emitted from a vehicle-mounted controller (not shown) mounted on a vehicle body to perform an automatic braking control such as traction control or vehicle stability control; and a rotational-position signal emitted from the resolver 40 .
  • the base plate 43 is provided thereon with a cover 53 for the resolver 40 and the drive controller 42 .
  • the motor 39 and the drive controller 42 are disposed on the base plate 43 , they can be readily unitized into the motor/controller unit. Further, since the base plate 43 is disposed between the motor 39 and the drive controller 42 , the drive controller 42 can be shielded from noise generated by the motor 39 . Further, an electrical connection between the resolver 40 and the drive controller 42 can be easily made, since the resolver 40 and the drive controller 42 are disposed adjacent to each other on the base plate 43 .
  • the base plate 43 is made of aluminum, as a complicated shape can be formed by aluminum die casting or aluminum foundry. However, the material of the base plate 43 is not limited to aluminum, and a pressed steel plate or a molded resin can be used instead.
  • the vehicle-mounted controller uses a brake-pedal sensor to detect a force (or an amount of displacement) that a driver exerted on a brake pedal. Based on the detected value, the vehicle-mounted controller transmits a braking-force signal to the drive controller 42 of the electric disk brake 1 of each wheel.
  • the drive controller 42 outputs a drive voltage to the motor 39 , based on the braking-force signal sent from the vehicle-mounted controller, to rotate the motor rotor 48 to a desired rotation angle, using a desired torque.
  • Rotation of the motor rotor 48 is reduced by the differential reduction mechanism 20 at a predetermined speed reduction ratio and is converted by the ball ramp mechanism 21 into a linear motion to move the piston 14 forward, which presses the brake pad 5 disposed on one side against the disk rotor 2 .
  • This reaction force moves the caliper body 8 along the slide pin 6 of the carrier 3 , whereby the claw portion 12 presses the brake pad 4 disposed on the other side against the disk rotor 2 .
  • the motor rotor 48 is rotated in a reverse direction to move the piston 14 backward and disengage the brake pads 4 and 5 from the disk rotor 2 .
  • the vehicle-mounted controller uses various sensors to detect vehicle conditions such as a rotational speed of each vehicle, a vehicle speed, a vehicle acceleration, a steering angle, and a vehicle lateral acceleration. Based on these detected data, the vehicle-mounted controller controls rotation of the motor 39 to perform a boost control, an antilock control, a traction control, a vehicle stability control, and so on.
  • eccentric rotation of the eccentric portion 31 revolves the spur gear 32 .
  • the rotary disk 25 and the ring gear member 35 which are meshed with the external teeth 32 A and 32 B of the spur gear 32 , perform a differential rotation.
  • the ring gear member 35 and the adjustment screw 16 are normally prevented by the wave washer 38 A from rotating.
  • the rotary disk 25 can freely rotate within a play of the limiter 38 . Therefore, only the rotary disk 25 rotates, whereby the ball ramp mechanism 21 moves the piston 14 forward to press the brake pads 4 and 5 against the disk rotor 2 .
  • a spring force of the limiter 38 acts on the rotary disk 25 to lock the rotary disk 25 , and the adjustment screw 16 rotates with the ring gear member 35 against a retaining force of the wave washer 38 A. In this way, the adjustment screw 16 moves forward through a relative rotation of the male screw 17 and the female screw 18 to advance the piston unit 9 .
  • the motor 39 , the resolver 40 , the parking brake mechanism 41 , the drive controller 42 , and so on are mounted on the base plate 43 to sub-assemble the motor/controller unit 10 (a first assembling step).
  • the bearing 46 is first pressed into a bottom portion of the motor case 44 in this sub-assembling process; then the motor stator 45 is secured to an inner circumferential portion of the motor case 44 .
  • an end of the motor rotor 48 is passed through an inner circumference of the motor stator 45 and fitted into an inner circumference of the bearing 46 , which is pressed into the bottom portion of the motor case 44 .
  • the bearing 47 is pressed into the surface 43 A of the base plate 43 .
  • the other end of the motor rotor 48 is fitted into an inner circumference of the bearing 47 , while the motor case 44 is mounted on the surface 43 A of the base plate 43 .
  • the wire 45 A extending from the motor stator 45 is passed through a through-hole 43 C of the base plate 43 .
  • the resolver rotor 51 is secured to the other end of the motor rotor 48 , and the resolver stator 50 is mounted on the surface 43 B of the base plate 43 , such that the resolver stator 50 becomes coaxial with the resolver rotor 51 .
  • the lock mechanism 52 of the parking brake mechanism 41 is mounted on the surface 43 B of the base plate 43 .
  • the drive controller 42 is mounted on the surface 43 B of the base plate 43 , and the wire 45 A of the motor stator 45 and the wire 50 A of the resolver stator 50 are connected to the drive controller 42 .
  • the cover 53 for the surface 43 B of the base plate 43 is attached to the base plate 43 to complete the process of assembling the motor/controller unit 10 .
  • an electric current is applied to the drive controller 42 to rotate the motor 39 .
  • This inspection is carried out to check whether the motor rotor 48 rotates properly, whether a rotational-position signal is properly transmitted from the resolver 40 , whether the rotation of the motor rotor 48 and the rotational-position signal transmitted from the resolver 40 are synchronized, and so on.
  • the piston 14 , the ball ramp mechanism 19 , the differential reduction mechanism 20 , the pad wear compensation mechanism 21 , and so on are sub-assembled to form the piston unit 9 .
  • the piston unit 9 is inserted into the cylinder 11 of the caliper body 8 , and the adjustment screw 16 is screwed into the cylinder 11 .
  • the motor 39 of the motor/controller unit 10 is inserted into the adjustment screw 16 .
  • a base of the motor case 44 is inserted, through the other end (one side) of the through-hole of the cylinder 11 of the caliper body 8 , into the cylinder 11 , such that the base plate 43 is connected to an end portion of the caliper body 8 (a second assembling step).
  • piston unit 9 and the motor/controller unit 10 can be assembled in parallel processes, productivity can be enhanced. Further, the piston unit 9 and the motor/controller unit 10 can be inserted into and removed from the caliper body 8 through an end of the caliper body 8 opposite to the claw portion 12 ; therefore, assembly and disassembly can be facilitated. Since the piston unit 9 and the motor/controller unit 10 can be individually operated to inspect the operation, it is possible to detect in each of the individual units whether any defect exists during a manufacturing or repairing process. Therefore, quality inspection and defect checking can be conducted efficiently, and replacement of any defective component can be conducted for the units individually. Further, since the motor 39 and the drive controller 42 are integrated, wiring therebetween can be simplified, and a loss in power supplied to the motor 39 and adverse effects of noise can be reduced.
  • the caliper body 8 and the piston unit 9 are connected by the male screw 17 of the adjustment screw 16 and the female screw 18 of the cylinder 11 .
  • the area of engagement between the caliper body 8 and the piston unit 9 is reduced, which can facilitate dimensional control. Further, any load can be efficiently transmitted and supported by the connection between the male screw 17 and the female screw 18 ; therefore, a rigidity of the caliper can be enhanced, and the caliper can be reduced in size.
  • the drive controller 10 of the motor 39 is disposed on an upper position of the cylinder 11 of the caliper body 8 , that is, an outer circumference of the motor 39 .
  • the cover 53 is disposed in the vicinity of the resolver 40 . In this way, the axial dimension of the electric caliper 54 can be reduced.
  • the drive controller 10 of the motor 39 is disposed at a rear portion of the piston unit 9 .
  • the bearing 47 of the motor rotor 48 is disposed, not on the base plate 43 , but on the motor case 44 A.
  • the motor case 44 of the motor 39 does not abut on the inner circumference of the cylinder 11 .
  • the base plate 43 on which the motor 39 is mounted abuts on the inner circumference of the cylinder 11 to determine a position of the motor 39 in a radial direction. In this way, an increase in the axial dimension can be reduced to a minimum, while the radial dimension can also be reduced.
  • the caliper body 8 and the motor/controller unit 10 are assembled, precision is required in two respects, namely, in attaching the motor case 44 to the base plate 43 , and in fitting the motor case 44 into the cylinder 11 . In the present embodiment, however, precision is required only in fitting the base plate 43 into the cylinder 11 . In this way, the manufacturing process is facilitated. Further, coaxial arrangement of the bearings 46 and 47 of the motor 39 can be made easily. Further, the motor 39 alone can be operated to rotate the motor rotor 48 . This makes it possible to inspect the motor 39 alone.
  • the diameters of the bearing 47 and a portion of the motor rotor 48 supported by the bearing 47 are increased to dispose the resolver 40 in an inner circumferential portion of the bearing 47 and the supported portion of the motor rotor 48 .
  • the resolver 40 is disposed on the same side of the base plate 43 as the motor 39 .
  • the ring-shaped resolver rotor 51 is fitted into an inner circumference of the portion of the motor rotor 48 supported by the bearing 47 , while the resolver stator 50 , which is disposed to face an inner circumferential surface of the resolver rotor 51 , is secured to the base plate 43 .
  • the drive controller 10 is disposed at a rear portion of the piston unit 9 . Therefore, axial and lateral dimensions can be reduced.
  • the motor and the controller are integrated to form a motor/controller unit. Therefore, an assembling process can be facilitated, and operation of the motor/controller unit can be inspected before the unit is combined with other parts.
  • the ball ramp mechanism 19 is used as a rotary-to-linear motion conversion mechanism; however, another conventional rotary-to-linear motion conversion mechanism such as a ball-screw mechanism, a roller-screw mechanism, or a roller ramp mechanism can be used instead.
  • the motor case 44 , the motor stator 45 , and the motor rotor 48 can be integrated as a motor unit.
  • the motor unit can be incorporated into the caliper body 8 , and can then be integrated with the drive controller 42 . In this way, before being incorporated into the caliper body 8 , the motor unit can be operated and inspected by being connected to a drive source for transmitting a drive signal, rather than being connected to the drive controller 42 .

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Braking Arrangements (AREA)
US11/723,313 2006-03-31 2007-03-19 Electric disk brake, caliper for the electric disk brake, motor/controller unit for the electric disk brake, and method for assembling the caliper for the electric disk brake Expired - Fee Related US7950503B2 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
JP2006-099761 2006-03-31
JP2006099761A JP4826942B2 (ja) 2006-03-31 2006-03-31 電動ディスクブレーキ、及び電動ディスクブレーキの組立方法
JP99761/2006 2006-03-31

Publications (2)

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US20070227838A1 US20070227838A1 (en) 2007-10-04
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US20090057074A1 (en) * 2007-08-30 2009-03-05 Tsuruta Tomohiko Electric brake device
US20090101454A1 (en) * 2007-10-22 2009-04-23 Keisuke Nanri Disk brake and method of producing the same
US20110031074A1 (en) * 2009-07-31 2011-02-10 Hideaki Ishii Electric motor-driven brake apparatus
US11493103B2 (en) * 2019-10-08 2022-11-08 Hyundai Mobis Co., Ltd. Electric brake apparatus of vehicle

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US8393442B2 (en) * 2008-08-14 2013-03-12 Hamilton Sundstrand Corporation High gain asymmetry brake
DE102009046044B4 (de) * 2008-11-03 2020-06-18 Continental Teves Ag & Co. Ohg Elektromechanisch betätigbare Scheibenbremse für Kraftfahrzeuge
WO2011155074A1 (fr) * 2010-06-08 2011-12-15 トヨタ自動車株式会社 Dispositif de frein électrique pour véhicule
JP5077603B2 (ja) * 2010-12-28 2012-11-21 日立オートモティブシステムズ株式会社 電動ディスクブレーキ
JP5943628B2 (ja) * 2011-04-13 2016-07-05 日立オートモティブシステムズ株式会社 ディスクブレーキ
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DE102012009900A1 (de) * 2012-05-18 2013-11-21 Knorr-Bremse Systeme für Nutzfahrzeuge GmbH Verschleißnachstellvorrichtung einer Scheibenbremse und entsprechende Scheibenbremse
FR2990912B1 (fr) * 2012-05-23 2014-07-04 Bosch Gmbh Robert Servofrein electro-hydraulique a boitier en matiere plastique moule en deux parties
JP6137805B2 (ja) * 2012-07-26 2017-05-31 曙ブレーキ工業株式会社 電動式ディスクブレーキ装置
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JP6149675B2 (ja) * 2013-10-09 2017-06-21 株式会社アドヴィックス 二輪車用ブレーキ装置
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JP6352202B2 (ja) * 2015-02-16 2018-07-04 株式会社ミツバ ブレーキ用アクチュエータおよびブレーキ装置
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CN111059177A (zh) * 2019-12-05 2020-04-24 天津英创汇智汽车技术有限公司 一种电子制动助力装置用的减速齿轮布置方式
US11794877B2 (en) * 2020-12-21 2023-10-24 Hamilton Sundstrand Corporation Integrated assymmetry brake mechanism
CN115589102A (zh) * 2022-10-20 2023-01-10 东莞市本末科技有限公司 直驱电机直插式驻车机构及直驱电机

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US20090057074A1 (en) * 2007-08-30 2009-03-05 Tsuruta Tomohiko Electric brake device
US8220594B2 (en) * 2007-08-30 2012-07-17 Nippon Soken, Inc Electric brake device
US20090101454A1 (en) * 2007-10-22 2009-04-23 Keisuke Nanri Disk brake and method of producing the same
US8807298B2 (en) * 2007-10-22 2014-08-19 Hitachi, Ltd. Disk brake and method of producing the same
US20110031074A1 (en) * 2009-07-31 2011-02-10 Hideaki Ishii Electric motor-driven brake apparatus
US11493103B2 (en) * 2019-10-08 2022-11-08 Hyundai Mobis Co., Ltd. Electric brake apparatus of vehicle

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CN101046234A (zh) 2007-10-03
JP2007271031A (ja) 2007-10-18
EP1840405A1 (fr) 2007-10-03
EP1998067B1 (fr) 2010-06-02
JP4826942B2 (ja) 2011-11-30
DE602007006924D1 (de) 2010-07-15
EP1998067A1 (fr) 2008-12-03
EP1840405B1 (fr) 2008-11-12
CN101046234B (zh) 2012-03-21
US20070227838A1 (en) 2007-10-04
DE602007000238D1 (de) 2008-12-24

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